Yamaha Motor India Private Fazer Service Manual

SERVICEMANUAL

GENINFOIMPORTANT INFORMATION1-3WARNINGIf the Circlip is fitted the wrong way it wouldcause it to jump off its groove and damagerelated components.WAR

ENGENGINE INSPECTION AND REPAIR4-26PRIMARY DRIVE GEAR INSPECTION1. Inspect :• Primary Drive Gear teeth ¿• Primary Driven Gear teeth ÀWear/damage Ÿ Rep

ENGENGINE INSPECTION AND REPAIR4-27PUSH ROD INSPECTION1. Inspect :• Ball ¿• Push Rod #1 ÀWear/damage/Bend Ÿ Replace2. Inspect :• Push Rod # 2 ¿Wear/da

ENGENGINE INSPECTION AND REPAIR4-28SHIFT FORK SHIFT CAM INSPECTION1. Inspect :• Shift Fork follower ¿• Shift Fork Pawl ÀScoring/bends/wear/damage Ÿ Re

ENGENGINE INSPECTION AND REPAIR4-295. Measure :• Axle runout (Main and Drive)Use a centering device and a dial gauge ¿Out of specifications Ÿ Replace

ENGENGINE INSPECTION AND REPAIR4-30OIL PUMP INSPECTION1. Measure :• Tip clearance ç(between the inner rotor ¿ and the outerrotor À) using feeler gauge

ENGENGINE INSPECTION AND REPAIR4-31CIRCLIPS AND WASHERS1. Inspect :• Circlips ¿• WashersDamage/looseness/bends Ÿ ReplaceBEARINGS AND OIL SEALS1. Inspe

ENGENGINE ASSEMBLY AND ADJUSTMENTSENGINE ASSEMBLY AND ADJUSTMENTS4-32VALVES, ROCKER ARM AND CAMSHAFT¿ Valve CottersÀ Valve Spring RetainerÁ Valve Spri

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-33WARNINGFor Engine Assembly, replace the followingparts with new ones :• O-Rings• Gaskets• Oil Seals• Copper Wash

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-344. Install :• Plate ¿• Bolt À3. Install :• Rocker Arm as shown in figure• Rocker Arm Shaft by pushing it incompl

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-35CRANKSHAFT¿ Crank PinÀ Crank ShaftÁ Connecting Rod Big end Bearingà Crankshaft BearingÄ Wood-ruff KeyÅ G

GENINFOYAMAHA SPECIAL SERVICE TOOLSYAMAHA SPECIAL SERVICE TOOLS1-4The appropriate Yamaha Special Service Tools are necessary for proper maintenance of

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-36CRANKSHAFT1. Insert :• CrankShaft in the Crankcase (L.H.)2. Attach :• Crankshaft Installing Tool on CrankshaftWA

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-37TRANSMISSION¿ Drive SprocketÀ Oil SealÁ Bearing 4th Wheel Gearà Drive AxleÄ 2nd Wheel gearÅ 3rd Wheel Ge

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-38SHIFTER¿ Shift Fork Guide Bar (long)À Shift Fork # RÁ Shift Fork # L Shift Camà SegmentÄ Shift Fork Guide Bar (

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-39TRANSMISSION, SHIFT CAM ANDSHIFT FORK INSTALLATION1. Measure :• Axle Main Assembled length ç2. Install :• Push r

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-40CRANKCASE¿ Crankcase #1 (LH)À Dowel PinsÁ Crankcase Breather Hose Crankcase #2 (RH)à Holder Clutch CableTi

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-41CRANKCASE LH1. Apply :• Sealant on the Crankcase Mating surfaces2. Install :• Dowel Pins ¿NOTE : Do not allow an

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-42CDI MAGNETO¿ Timing ChainÀ Guide Stopper # 1 and # 2Á CDI Rotor Assy Wood-Ruff Keyà Stator Assy.Ä GasketÅ

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-43SPROCKET DRIVE1. Install• Sprocket Drive ¿• Drive Sprocket Washer À2. Tighten• Bolt Á (Drive Sprocket) using th

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-44SHIFT SHAFT AND KICK STARTER¿ Shift ShaftÀ Torsion SpringÁ Stopper Lever Return Springà SegmentÄ Kick Starter A

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-455. Install :• Shift Shaft Assembly ÂNOTE : Apply Oil to the Stopper Pin and hook the Springends on the Stopper p

GENINFOYAMAHA SPECIAL SERVICE TOOLS1-518. T.F.F. Oil Seal Installation ToolYSST-275This tool is used to remove the Crank Shaftfrom the Crank Case.9.

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-462. Install :Following parts on the Axle Drive Ä• Circlip ¿• Washer À• Kick Idle gear Á• Washer • Circlip ÃNOTE

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-47¿ Clutch SpringÀ Pressure PlateÁ Push Plate Push Rod #1à Friction PlateÄ Clutch PlateÅ Clutch BossÆ Thrust Wash

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-48PRIMARY DRIVE GEAR INSTALLATION1. Install :• Primary Drive Gear ¿• Key• Washer À2. Tighten :• Nut ÁNOTE : Hold t

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-494. Bend :• Lock Washer tab(along a flat side of the end)5. Install :• Friction Plate ¿ 5 Nos• Clutch Plate À 4

ENGALIGNED NON ALIGNEDENGINE ASSEMBLY AND ADJUSTMENTSENGINE ASSEMBLY AND ADJUSTMENTS4-506. Install :• Ball ¿7. Install :• Push Rod # 1 ¿• Push Plate À

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-51ENGINE ASSEMBLY AND ADJUSTMENTSWARNINGCAUTION:Take care not to overtighten the Adjuster À andremove the freeplay

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-52¿ CylinderÀ Gasket CylinderÁ Dowel Pins Piston Ringsà Piston Pin CirclipsÄ PistonÅ Pin PistonÆ O’ Ring

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-53¿ Bolt FlangeÀ WasherÁ Bolt Valve Cover (intake)à O-RingÄ Valve Cover (exhaust)Å Cylinder HeadÆ Dowel P

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-54CAM SPROCKET AND TIMING CHAIN¿ GasketÀ Timing Chain Tensioner AssemblyÁ Guide Stopper # 2 Cam Sprocketà Timing

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-553. Install :• Dowel Pins ¿ - 2 Nos.• Gasket (Cylinder) ÀPISTON RING, PISTON AND CYLINDERINSTALLATION1. Install i

GENINFOSPECIAL SERVICE TOOLS1-6This tool is used to loosen or tighten theSpeedometer Gear Nut.21. Spanner - Speedometer Gear Nut.YSST - 237This fixtur

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-56Cylinder head Installation1. Install• Dowel Pins ¿• Gasket ( Cylinder Head) À• Guide Stopper#1 Á4. Install :• Pi

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-572. Install :• Cylinder Head• Bolt with Washer (Cylinder Head)NOTE : • Apply Engine Oil onto the Bolt thread• Tig

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-586. Check :• Magneto Rotor Slit ç Third mark inAnticlockwise direction.Align with stationary pointer è in theCran

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-5912. Install• O-Ring (intake manifold)• Intake Manifold ¿13. Tighten• Bolts (intake manifold) À 2 Nos.11. Install

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-6014. Install :• Spark Plug15. Install :• Plug Drain ¿ENGINE MOUNTINGWhen remounting the Engine, reverse the re-mo

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-615. Install :• Gasket• Exhaust pipe ¿• Bolts Exhaust Pipe À - 2 nos• Bolt (Muffler) Á6. Install :• Shift Pedal ¿7

ENGENGINE ASSEMBLY AND ADJUSTMENTS4-6211. Install:• CarburetorRefer to “CARBURETOR “ section inChapter 5 page no 5-712. Tighten:• Air Filter Case Scre

CARBCHAPTER 5CARBURETIONCARBURETOR VIEW ...5-1REMOVAL ...

CARBCARBURETORCARBURETOR5-11 SCREW (TOP COVER)2 TOP COVER3 PISTON VALVE SPRING4 HOLDER (JET NEEDLE)5 JET NEEDLE RETAINER SPRING6 RING7 JET NEEDLE E-RI

CARBCARBURETOR5-26. Remove• Throttle Cable - ¿7. Unscrew• Clamp Front/Rear• Remove carburettor from Engine.4. Disconnect :• Air Vent Hose ¿• Fuel Hose

GENINFOSERVICE INSTRUMENTSThe following Service Instruments are necessary for complete and accurate tune up of MotorcycleSERVICE INSTRUMENTS1-75. Vern

CARBDISASSEMBLY1. Open :• Screw (Pan Head) 2-Nos- ¿2. Remove :• Cover À• Spring Á• Diaphragm with Piston Valve ÂDISASSEMBLYNOTE: The following parts c

CARBCarburetor Body1. Inspect :• Cracks/damage Ÿ Replace• Fuel Passages Blockage Ÿ Clean withpetrol and Compressed air.• Contamination in jet housings

CARBINSPECTION Starter Assembly1. Inspect :• Starter plunger movement• Starter spring• Starter wire Piston Valve1. Check :• Free movementInsert the Pi

CARBASSEMBLYReverse the disassembly procedure.1. Wash• All the parts in clean petroleum basedsolvent• Always use new ‘o’ Rings2. Install :• Pilot scre

CARBINSTALLATION5-7INSTALLATIONReverse the “REMOVAL” procedure1. Carburettor Inlet Manifold and tighten Airfilter Hose. Screw Front/Rear Clamp2. I

CARBCARBURETOR TUNING8. Adjust :• Idling speed by Throttle Stop Screw ¿5-8Turning in Ÿ RPM IncreasesTurning Out Ÿ RPM DecaresesEngine Idling Speed :

CARBWARNINGCAUTION:Do not disturb settings of the Carburetor ifthe Engine performance is O.K.• If required, must record the existing set-ting (No. of

CARBCARBURETOR TUNING5-10By Bending Down Ÿ Float Height increaseBy Lifting Up Ÿ Float Height Decrease• Otherwise adjust Float level by bending theFloa

CARBMultimeter YTPS+ Terminal of Blue wire- Terminal of Black wire• Check TPS output VoltageMultimeter YTPS+ Terminal of Yellow wi

CARBCARBURETOR TUNINGAIR INDUCTION SYSTEMAIR INJECTIONThe air induction system burns unburnedexhaust gases by injecting freshair(secondary air) into t

GENINFOSERVICE INSTRUMENTS1-89. Tyre pressure gauge10. Vaccum Gauge11. Torque Wrench(10-50 Ft-Lb)(20-100 Ft-Lb)12. Feeler gaugeThis instrument is us

CHASCHAPTER 6CHASSISFRONT WHEEL AND FRONT BRAKE...6-1FRONT WHEEL ...

CHASFRONT WHEEL¿ Cotter PinÀ Axle NutÁ Speedometer Cable Assy. Wheel Axleà SpacerÄ Brake Shoe Plate Assy.Å Dust Seal/CollarÆ Front WheelFRONT

CHASFRONT BRAKE¿ Brake Shoe Assy.À Oil SealÁ Gear drive Lever Camshaftà Indicator PlateÄ CamshaftFRONT WHEEL AND FRONT BRAKES6-2Å BushÆ

CHASFRONT WHEEL AND FRONT BRAKESWARNING• Securely support the Motorcycle on thecentre stand so that there is no danger ofit falling over.• Park the Mo

CHASFront Wheel Inspection :1. Inspect• Front Wheel Axle(by rolling it on a flat surface)Bends Ÿ Replace2. Inspect :• Front TyreWear/damage Ÿ Replace

CHAS5. Measure :• Front Wheel runout using a height gaugeOver the specified limits Ÿ Correct/Replace6. Inspect :• Front Wheel BearingsBearings allow f

CHASFRONT WHEEL AND FRONT BRAKESFRONT BRAKE INSPECTION1. Inspect :• Brake Lining surfaceGlazed areas Ÿ ReplaceUse Coarse Sand Paper for polishing ofBr

CHASFRONT WHEEL AND FRONT BRAKES6-7WARNINGAfter installing the Brake Camshaft, removethe excess grease5. Install :• Brake Shoe Plate Assembly ¿NOTE :M

CHASFRONT WHEEL INSTALLATIONReverse the “REMOVAL” procedureNote the following points1. Lubricate :• Axle Front Wheel• Bearings• Oil Seal (lips)• Drive

CHAS5 Install :• Meter Cable ¿• Clip À• Brake Cable Á thru nozzle• Bush • Nut6. Check :• Front Brake for proper operationImproper operation Ÿ Recheck

SPECCHAPTER 2.SPECIFICATIONSGENERAL SPECIFICATIONS ...2-1MAINTENANCE SPECIFICATIONSENGINE ...

CHASREAR WHEEL¿ AdjusterÀ PinÁ CompressionSpring Cotter Pinà Tension BarÄ Axle NutÅ Chain PullerÆ SpacerÇ Rear Wheel AssemblyÈ Brake Shoe

CHASREAR BRAKE¿ Brake Shoe KitÀ Cam LeverÁ Indicator Plate Camshaftà SpringREAR WHEEL AND REAR BRAKE6-11Ã

CHASREAR WHEEL AND REAR BRAKE6-12WARNING• Securely support the Motorcycle on centrestand so that there is no danger of it fall-ing over• Stand the Mo

CHASREAR WHEEL AND REAR BRAKE6-13REAR WHEEL INSPECTION1. Inspect :• Axle Rear Wheel• Rear Wheel• Bearings Rear Wheel• Oil SealsRefer to “FRONT WHEEL I

CHASREAR WHEEL AND REAR BRAKE6-14WARNINGAlways use a new Cottor PinREAR WHEEL INSTALLATIONReverse the “REMOVAL” procedure1. Install :• Chain Adjuster

CHASDRIVE CHAIN AND SPROCKETS¿ Chain CaseÀ Crankcase Cover 3Á Drive Sprocket Clip Chain Jointà Link PlateÄ Chain JointÅ Drive ChainÆ SpacerÇ

CHASDRIVE CHAIN AND SPROCKETS6-165. Remove :• Rear wheel Assy. removalRefer to Rear Wheel removal on page 6-12• Rear wheel Sprocket Assy.4. Remove :•

CHASDRIVE CHAIN INSPECTION1. Inspect :• Drive Chain stiffnessStiffness Ÿ Clean and Lubricate or replaceDRIVE CHAIN AND SPROCKETS6-174. Clean :• Drive

CHAS6-18DRIVE CHAIN AND SPROCKETSCLUTCH HUB INSPECTION1. Inspect :Clutch HubWear/damage/cracks Ÿ ReplaceDRIVEN SPROCKET AND DRIVE CHAININSTALLATION1.

CHASDRIVE CHAIN AND SPROCKETSWARNINGCAUTION:Be sure to install the Chain Joint Clip to the di-rection as shown6-193. Install :• Drive Chain ¿• Chain J

SPECDESCRIPTION SPECIFICATIONModel : FAZERModel Code : 5YY1Engine model code: 5YY1DIMENSIONS:Overall length 2065 mmOverall width 730 mmOverall height

CHASFRONT FORK6-20FRONT FORK¿ Front FenderÀ Cap Bolt with GrometÁ Holder Cable O Ringà CollarÄ Spring SeatÅ Fork SpringÆ Seal DustÇ Ring SnapÈ Washer

CHASFRONT FORK6-21WARNINGSecurely support the Motorcycle so there isno danger of it falling overFRONT FORK DISASSEMBLY1. Remove• Bolt Upper -TFF Á2. D

CHASFRONT FORK6-22WARNINGCAUTION:Never reuse the Oil Seal6. Remove :• Ring snap• Washer• Oil Seal ¿ using Oil Seal Remover À5. Remove :• Bolt (Damper

CHASFRONT FORKFRONT FORK INSPECTION1. Inspect :• Inner Tube bendingScratches/bends/damage Ÿ Replace2. Measure :• Fork Spring length çOver the specifi

CHASFRONT FORK6-24WARNINGAllow the Cylinder Complete to slide slowlydown the Inner Fork Tube until it protrudesfrom the bottom, being careful not to d

CHASFRONT FORK6-25WARNINGCAUTION:Make sure that the Oil Seal numbered sidefaces upward7. Install :• Washer ¿• Ring Snap À• Dust Seal Á5. Tighten :• Bo

CHASFRONT FORK INSTALLATIONReverse the “REMOVAL PROCEDURE”Note the following points1. Install• Front Fork• Temporarily tighten Pinch Bolt(Underbracket

CHASSTEERING HEAD AND HANDLEBAR6-27STEERING HEAD AND HANDLEBAR¿ Bolt SteeringÀ Holder Handle bar UpperÁ Handlebar Grip Assembly (right)à Ha

CHASSTEERING HEAD AND HANDLEBAR6-28WARNINGSecurely support the motorcycle so thatthere is no danger of it falling overStand the motorcycle on a level

CHASSTEERING HEAD AND HANDLEBAR6-29WARNINGSecurely support the Steering Shaft so thatthere is no danger of it falling downWARNINGDo not attempt to str

SPECDESCRIPTION SPECIFICATIONClutch type : Wet, Multiple discTransmission :Primary reduction system Helical gearPrimary reduction ratio 68/19 (3.579 :

CHAS12STEERING HEAD AND HANDLEBARSTEERING INSPECTION1. Wash the Bearing and Ball Races with a sol-vent2. Inspect :• Bearing Races ¿• Ball Cage Bearing

CHASSTEERING HEAD AND HANDLEBAR4. Install :• Front ForkRefer to “FRONT FORK” Section, Page no6-27• Front Fender• Front WheelRefer to “FRONT WHEEL” Sec

CHASREAR SHOCK ABSORBER AND SWING ARMREAR SHOCK ABSORBER AND SWINGARM¿ Rear Shock AbsorberÀ Axle NutÁ Swing arm Tension Barà Seal Guard6-32

CHASREAR SHOCK ABSORBER AND SWING ARMREMOVAL1. Stand the Motorcycle on a level surface.2. Remove :• Side Covers (left and right)• Seat• Cover Chaincas

CHASREAR SHOCK ABSORBER AND SWING ARMINSPECTION1. Inspect :• Swingarm loosenessLooseness exists Ÿ Tighten the PivotShaft nut or replace Bushes• Swinga

ELECCHAPTER 7ELECTRICALCIRCUIT DIAGRAM ...7-1LOCATION OF ELECTRICAL COMPONENTS ...

ELECCIRCUIT DIAGRAM7-1

ELEC¿ Main SwitchÀ Flasher Relay AssyÁ C.D.I. Unit Assy Batteryà FuseÄ Stop Switch RearÅ Neutral Switch AssyÆ Rectifier / Regulator AssyÇ Ignition Co

ELECCHECKING OF CONNECTIONSDealing with wire pressed stains, rust,moisture etc. on the connector.1. Disconnect• Connector ¿2. Dry each terminal with a

ELECIGNITION SYSTEM/ CHARGING SYSTEMIGNITION SYSTEM, CHARGING SYSTEM AND TACHOMETER SYSTEMTROUBLE SHOOTINGIF THE IGNITION SYSTEM FAILS TO OPERATE.(NO

SPECDESCRIPTION SPECIFICATIONBrake :Front brake Type Drum Brake (Dia 150 mm)Operation Right hand operationRear brake Type Drum brake (Dia 130 mm)Opera

ELECIGNITION SYSTEM / CHARGING SYSTEMPROCEDURE STEPS1. SPARK PLUG• Check the spark plug condition• Check the Spark Plug type• Check the Spark Plug ga

ELECIGNITION SYSTEM / CHARGING SYSTEM3A. IGNITION COIL RESISTANCE (Primary)• Disconnect the Ignition Coil ConnectorFrom the Wire harness• Connect the

ELEC5. SENSOR COIL RESISTANCE• Disconnect the sensor Coil Coupler fromthe Wiring Harness• Connect the Multimeter (Ω X 100) to thesensor coil coupler•

ELEC7. RECTIFIER CUM REGULATOR UNIT• Check the Charging VoltageProcedure Steps• Connect the Tachometer to Spark plug lead• Connect the Multimeter (

ELECCHARGING SYSTEMTROUBLE SHOOTINGPROCEDURECHECK1. Fuse2. Battery3. Charging voltage4. Charging coil resistance5. Wiring system (entire charging syst

ELECLIGHTING SYSTEMTROUBLE SHOOTINGIF THE HEAD LIGHT, HI BEAM INDICATOR LIGHT, TAILLIGHT AND METER LIGHTDO NOT WORKPROCEDURECHECK1. Lighting Coil resi

ELECLIGHTING SYSTEM1. LIGHTING COIL RESISTANCE• Remove the C.D.I. Magento Coupler fromthe wiring Harness• Connect the Multimeter (Ω X 1) to the Light-

ELECLIGHTING SYSTEM5. WIRING CONNECTIONS• Check entire lighting system for poor Con-nections refer to “WIRING DIAGRAM”PageCheck the Lighting Coil resi

ELECLIGHTING SYSTEM1. BULB AND BULB SOCKET• Check the Bulb and Bulb Socket forcontinuity.C. If the Tail Light does not workReplace Bulb and/or Bulb so

ELECSIGNAL SYSTEMSIGNAL SYSTEMCIRCUIT DIAGRAM : DCTROUBLE SHOOTINGIF THE FLASHER LIGHT, BRAKE LIGHT AND INDICATOR LIGHTS DO NOT WORKIF THE HORN DOES

L-1FAZERSERVICE MANUALYAMAHA MOTOR INDIA PVT. LIMITEDAll rights reserved.Any reprinting or unauthorised use withoutthe written permission ofYAMAHA MOT

SPECDESCRIPTION SPECIFICATIONCylinder :Bore size 54.000 ~ 54.018 mm(in five grades)Piston :Piston to Cylinder Clearance 0.020 ~ 0.027 mm<Limit>

ELECSIGNAL SYSTEM1. FUSERefer to “FUSE INSPECTION SECTION “ inChapter 3, Page 3-302. BATTERY• Check the Battery conditionRefer to “BATTERY INSPECTION

ELECSIGNAL SYSTEM1. HORN SWITCH• Disconnect the Handlebar Switch Couplerfrom Wireharness.• Check the continuity between the “Pink” and“Black” with swi

ELECSIGNAL SYSTEM1. BULB AND BULB SOCKETS• Check the Bulb and Bulb sockets for con-tinuity.B. If the Brake Light does not work.Replace Bulb and/or Bul

ELECSIGNAL SYSTEM1. BULB AND BULB SOCKET • Check the Bulb and Bulb Socket continuityC. If the flasher light and/or turnindicator light fails to blink.

ELECSIGNAL SYSTEM5. VOLTAGE• Connect the Multimeter (DC20V) to theBulb Socket connector• Turn the Main Switch to ‘ON’• Turn the Turn Switch to left or

ELECSIGNAL SYSTEMCheck the connection of the entire signalsystem.Refer to “CIRCUIT DIAGRAM” Page no 7-14.1. BULB AND BULB SOCKET• Check the bulb and b

TRBLSHTGCHAPTER 8TROUBLE SHOOTINGSTARTING FAILURE/ HARD STARTING ...8-1POOR IDLE SPEED PERFORMANCE...

TRBLSHTGSTARTING FAILURE / HARD STARTINGNOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,ho

TRBLSHTGPOOR IDLE SPEED PERFORMANCEIGNITION SYSTEMSpark Plug• Improper Plug gap• Worn Electrodes• Wire between Terminals broken• Improper heat range•

TRBLSHTGPOOR SPEED PERFORMANCEIgnition System• Dirty Spark Plug• Improper heat range• Faulty C.D.I. Unit• Faulty Sensor CoilFuel System• Partially Cl

SPECDESCRIPTION SPECIFICATIONCylinder head :<Warp limit> <0.03 mm (0.0012 in)>* Lines indicate straightedgemeasurement.Camshaft :Drive met

TRBLSHTGFAULTY GEAR SHIFTING / OVERHEATINGFAULTY GEAR SHIFTINGHARD SHIFTINGRefer to “CLUTCH DRAGGING’’ Page no 8-3SHIFT PEDAL DOES NOT MOVEShift Shaft

TRBLSHTGFRONT FORK MALFUNCTION /UNSTABLE HANDLINGFRONT FORK MALFUNCTIONOIL LEAKAGE• Bent damaged or rusty Inner Tube• Damaged or cracked Outer Tube• D

TRBLSHTGFAULTY SIGNAL AND LIGHTING SYSTEMFAULTY SIGNAL AND LIGHTING SYSTEMHEADLIGHT DIM• Improper Bulb• Too many electric accessories• Hard charging•

YAMAHA MOTOR INDIA PVT. LIMITED19/6, Mathura Road, Faridabad - 121 006 INDIAPRINTED IN INDIA5YY (FAZER)1Y16(WM-01)-204-10-04-E

SPECDESCRIPTION SPECIFICATIONStem outside diameter IN 5.975 ~ 5.990 mmEX 5.960 ~ 5.975 mm <Limit> IN <5.950 mm>EX <5.935 mm>Guide i

SPECDESCRIPTION SPECIFICATIONClutch :Friction plate thickness 2.90 ~ 3.10 mm Quantity 5 pcs. <Friction plate wear limit> <2.80 mm>Clutc

SPEC2-8MAINTENANCE SPECIFICATIONSTIGHTENING TORQUE (ENGINE)Part to be tightened Parts Thread Q’ty Tightening torque Remarkname size Nm m.kg ft.lbCyl

SPECTightening sequence2-9MAINTENANCE SPECIFICATIONSCylinder HeadCrankcaseRight - handLeft - handtTIGHTENING TORQUE (ENGINE)Part to be tightened Parts

SPECDESCRIPTION SPECIFICATIONSteering system :Steering Bearing type Retainer Ball CageNo./size of steel balls (upper) 19 pcs. / 1/4 in(lower) 16 pcs.

SPECDESCRIPTION SPECIFICATIONFront Drum Brake :Type Leading, TrailingBrake Drum inside diameter 150mm<Wear limit> <151>Lining Thickness 4.

SPECTIGHTENING TORQUE (CHASSIS)MAINTENANCE SPECIFICATIONS2-12PARTS TO BE TIGHTENED THREAD TIGHTENING TORQUESIZE Nm m.kg ft.lbFront Engine Stay a

SPECDESCRIPTION SPECIFICATIONVoltage : 12VIgnition system :Ignition timing (B.T. D. C) 7º ± 2º BTDC at 1400 rpm.Advancer Type Electrical typeCDI : Dig

R-1FOREWORDThis Workshop Manual has been prepared for use by the Yamaha MotorIndia Private Ltd. Authorised Dealerships and their service personnel to

SPECMAINTENANCE SPECIFICATIONSCircuit Breaker :Type FuseAmperage for individual circuit X quantity :Main 10A X 1pc.Reserve 10A X 1pc.2-14

SPECGENERAL TORQUE SPECIFICATIONSThis chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque speci-fication for spec

SPECENGINELubrication points (part name) Lubricant typeOil Seal lips (all)Bearing Retainer (all)Bolt (Cylinder Head)O-ring (Cylinder Head Side Cover a

SPECLUBRICATION POINTS AND LUBRICANT TYPECHASSISLubrication points (part name) Lubricant typeGear Unit (Gear Meter and Drive)Oil Seal Lips (all)Pivot

SPECENGINE LUBRICATION ROUTEEngine Lubrication route2-18WARNINGCAUTION:DO NOT DAMAGE CRANK CASE SURFACES, OTHERWISE OIL LEAKAGE WILL START

SPECENGINE LUBRICATION ROUTEEngine Lubrication route2-19WARNINGCAUTION:FOR IMPROVED PERFORMANCE, ALWAYS USE YAMALUBE OIL

SPECENGINE BEARINGSENGINE BEARINGS2-20

SPECCABLE ROUTING¿ Handlebar switch (left)À Clutch cableÁ Starter Wire Speedometerà TachometerÄ Brake Cable frontÅ Throttle cableÆ Brake switch leadÇ

SPECCABLE ROUTING2-22¿ Headlight assemblyÀ Handlebar switch leadÁ Speedometer cable Cable guideà Clutch cableÄ HornÅ FuseÆ CDI unitÇ Clamp BatteryÈ S

SPECCABLE ROUTING¿ Throttle cable È A.I.S. UnitÀ High tension cord É Starter wireÁ Ignition Coil Ê Carburettor Breather Band - C.D.I. Pipeà Brake ca

L-2ENGENGINE ASSEMBLY AND ADJUSTMENTSPiston Pin replacer toolYSST - 607ENGINE ASSEMBLY13HOW TO USE THIS MANUALMANUAL ORGANISATIONThis manual consists

SPECCABLE ROUTING¿ C.D.I. UnitÀ Rectifier regulatorÁ Flasher relay Flasher light leadA Clamp the Wire Harness lead.B Pass the Wire Harness between Fr

INSPADJCHAPTER 3PERIODIC INSPECTION AND ADJUSTMENTSPERIODIC MAINTENANCE / LUBRICATION INTERVALS...3-1SIDE COVER, SEAT AND FUEL TANKREMOVAL...

INSPADJINTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS3-1

INSPADJPERIODIC MAINTENANCE/LUBRICATION INTERVALS3-2S. NO. ITEM OPERATIONSERVICESFREE PAID18 DRIVE CHAIN Check chain stack, alignment, adjust ifnecess

INSPADJREMOVAL SIDE COVER (LH)1. Remove• Side Cover (LH)ææææææææææææææææææææææææææææææææææRemoval steps :• Open the Lock ¿ using Main Switch Key.• Pul

INSPADJSIDE COVERS, SEAT AND FUEL TANK3-42. Remove• Bolt (Fuel Tank) ¿• Plate À• Damper Rubber Á• Fuel Tank ÂREMOVAL FUEL TANK1. Disconnect• Fuel Hose

INSPADJINSTALLATIONReverse the REMOVAL procedure.Note the following points.1. Install• Fuel Tank ¿• Damper Rubber À• Plate Á• Bolt • Fuel HoseSIDE CO

INSPADJVALVE CLEARANCE CHECKING AND ADJUSTMENTVALVE CLEARANCE CHECKING ANDADJUSTMENTNOTE : Valve clearance checking and adjustmentshould be made wit

INSPADJVALVE CLEARANCE CHECKING AND ADJUSTMENTææææææææææææææææææææææææææææææææææChecking steps :Measurement steps :• Rotate the Crankshaft anticlockwi

INSPADJIDLING CO. MEASUREMENT AND ADJUSTMENTIDLING CO. MEASUREMENT ANDADJUSTMENT1. Start the Engine and let it warm up by run-ning the Motorcycle appr

R-310.LubricantILLUSTRATED SYMBOLSIllustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s numberand content.GENINFOSPECINSPADJ

INSPADJIDLING ‘CO’ MEASUREMENT AND ADJUSTMENT/THROTTLE CABLE ADJUSTMENT5. Adjust :• ‘CO’ concentrationææææææææææææææææææææææææææææææææææAdjustment ste

INSPADJTHROTTLE CABLE ADJUSTMENT/SPARK PLUG INSPECTION• Loosen the Locknut ¿ on the ThrottleCable.• Turn the Adjuster À in or out until thespecified f

INSPADJSPARK PLUG INSPECTION/IGNITION TIMING CHECKING PROCEDURE3-116. Install :• Spark PlugNOTE : • Before installing a Spark Plug, clean the Gas-ke

INSPADJIGNITION TIMING CHECKING PROCEDURE3. Check :• Ignition timing*********************************************Checking steps :• Start the Engine a

INSPADJCOMPRESSION PRESSURE MEASUREMENTCOMPRESSION PRESSURE MEASUREMENTNOTE : Insufficient compression pressure will result inperformance loss.1. Ch

INSPADJENGINE OIL LEVEL INSPECTION/ENGINE OIL REPLACEMENTENGINE OIL LEVEL INSPECTION1. Stand the Motorcycle on a level surface us-ing the Center Stand

INSPADJENGINE OIL REPLACEMENT/EXHAUST SYSTEM INSPECTION4. Install :• Drain plug ¿ with Washer5. Fill :• Oil in Crankcase6. Check :• Engine oil levelRe

INSPADJAIR FILTER CLEANING1. Remove:• Side Cover (R.H.)• Air Filter Case Cap ¿ - Unscrew 4 Nos.Screws• Spring Wire À• Air Filter Element Á• Element gu

INSPADJCLUTCH CABLE ADJUSTMENTCLUTCH CABLE ADJUSTMENT1. Check :• Clutch Cable free play çOut of specification Ÿ Adjust,2. Adjust:• Clutch Cable free p

INSPADJFRONT BRAKE ADJUSTMENT/REAR BRAKE ADJUSTMENTCHASSIS3-18çTurning in ç Ÿ Free play is increased.Turning out è Ÿ Free play is decreased.Turning i

INDEXGENERAL INFORMATIONGENINFO1TROUBLE SHOOTINGTRBLSHTG8ELECTRICALELEC7CHASSISCHAS6CARBURETIONCARB5ENGINEENG4PERIODIC INSPECTION ANDADJUSTMENTSINSPAD

INSPADJREAR BRAKE ADJUSTMENT/BRAKE SHOE INSPECTIONææææææææææææææææææææææææææææææææææAdjustment steps :• Turn the Adjuster ¿ in or until the specifiedf

INSPADJDRIVE CHAIN SLACK ADJUSTMENTDRIVE CHAIN SLACK ADJUSTMENTNOTE:• Before checking and adjusting, rotate theRear Wheel several revolutions and chec

INSPADJDRIVE CHAIN SLACK ADJUSTMENT3-21WARNINGCAUTION:Do not loosen the Axle Nut after tighteningthe torque. If the axle nut grooves is notaligned wit

INSPADJSTEERING HEAD INSPECTION3-22WARNINGSecurely support the Motorcycle so thatthere is no danger of it falling over.STEERING HEAD INSPECTION1. Sta

INSPADJSTEERING HEAD INSPECTION• Check the Steering Stem by Turning it Lock toLock. If there is any binding, remove the Steer-ing Stem Assembly and in

INSPADJFRONT FORK INSPECTIONFRONT FORK INSPECTION1. Stand the Motorcycle on a level surface.2. Check:• Inner tubeScratches/damage ➔ Replace.• Oil seal

INSPADJREAR SHOCK ABSORBER ADJUSTMENTææææææææææææææææææææææææææææææææææAdjustment steps:• Turn the Adjuster Ring ¿ in or out.æææææææææææææææææææææææææ

INSPADJTYRE INSPECTION2. Inspect :• Tyre surfacesWear/damage Ÿ Replace¿ Tread DepthÀ Side wallÁ Wear indicator• Be sure to install the correct Tube

INSPADJSPOKE INSPECTION AND TIGHTENEING3-27WARNINGNever attempt to make any repairs to thewheel rim.WHEEL INSPECTION1. Inspect :• WheelsDamage/Bends Ÿ

INSPADJBATTERY INSPECTIONELECTRICAL3-28WARNINGCAUTION:When inspecting the Battery, make sure thatthe Breather Hose is routed correctly. If theBreather

GENINFOCHAPTER 1GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONFRAME SERIAL NUMBER...1-1ENGINE SERI

INSPADJBATTERY INSTALLATIONReplace the battery if:• Battery voltage does not rise to a specificvalue or bubbles fail to rise during charging.• Sulphat

INSPADJFUSE INSPECTIONFUSE INSPECTION1. Remove:• Side cover (left)Refer to “SEAT, SIDE COVERS ANDFUEL TANK” section Page no 3-3• Fuse holder ¿2. Inspe

INSPADJHEADLIGHT BEAM ADJUSTMENT/HEADLIGHT BULB REPLACEMENTHEADLIGHT BEAM ADJUSTMENT1. Loosen:• Bolt ¿2. Loosen:• Screw À - 2 Nos.3. Adjust :• Headlig

ENGCHAPTER 4ENGINE OVERHAULENGINE REMOVALSIDE COVERS, SEAT AND FUEL TANK REMOVAL ...4-1ENGINE OIL DRAIN ...

ENGCIRCLIPS AND WASHERS ...4-31ENGINE ASSEMBLY AND ADJUSTMENT...4-32

ENGENGINE REMOVALENGINE REMOVAL4-1It is not necessary to remove the Enginein order to remove the following parts.• Cylinder Head• Cylinder• Piston• Cl

ENG3ENGINE REMOVAL4-2FOOTREST ASSEMBLY1. Remove:• Bolt (footrest) ¿ - 2 Nos. (LH & RH)• Bolt Axle - Lower rear mounting À• Footrest AssemblyDRIVE

ENGENGINE REMOVAL4-3SHIFT PEDAL1. Remove• Bolt (Shift Pedal) ¿• Shift Pedal ÀBATTERY BOX1. Remove• Bolt (Battery Box) ¿ 3 nos• Battery Box ÀLEADS1.

ENGENGINE DISASSEMBLYENGINE DISASSEMBLY4-4CYLINDER HEAD, CYLINDER ANDPISTONNOTE: With Engine mounted on Motorcycle, the Cyl-inder Head, Camshaft and C

ENGENGINE DISASSEMBLY4-56. Remove :• Bolt (cam sprocket) ¿• Plate washer (cam sprocket) À• Cam sprocket ÁNOTE : Hold the Nut Rotor with socket spanner

GENINFOFRAME SERIAL NUMBERThe Frame Serial Number ¿ is stamped into theright side of the Steering Head Pipe.ENGINE SERIAL NUMBERThe Engine Serial Numb

ENGMAINTENANCE SPECIFICATIONS4-610. Remove :• Piston Pin Circlip ¿ 2 nos• Piston Pin À , using Piston Pin Replacer• Piston ÁNOTE : Before removing th

ENGENGINE DISASSEMBLY4-73. Remove:• Pressure Plate Bolts ¿ - 4 Nos• Clutch Springs À - 4 Nos• Pressure Plate Á with Push rod 1• Friction Plates  - 5

ENGENGINE DISASSEMBLY4-86. Remove :• Clutch Boss Nut ¿• Lock Washer À• Clutch Boss Á• Thrust Washer • Clutch Housing Õ Spacer Ä1. Remove :• Gear pum

ENGENGINE DISASSEMBLY4-9Kick Starter disassembly1. Remove :• Spacer ¿• Torsion spring À• Shim Á• Ratchet gear • Shim Õ Ratchet gear with return spri

ENGENGINE DISASSEMBLY4-10CDI MAGNETO REMOVAL1. Remove :• Nut (magneto)• Plain washerNOTE : • Loosen the Nut Magneto while holding theMagneto À with Ma

ENGENGINE DISASSEMBLY4-112. Remove :• Bolts (Crankcase LH-8 nos)NOTE : • Loosen the Bolts in a crisscross pattern.• Loosen each Bolts 1/4 turn at a ti

ENGENGINE DISASSEMBLY:TRANSMISSION AND SHIFTER4-12TRANSMISSION AND SHIFTER1. Remove :• Shift Fork Guide Bar ¿ (short)• Shift Fork Guide Bar À (long)•

ENGDISASSEMBLY OF CYLINDER HEAD,ROCKER ARMS, CAMSHAFT ANDVALVES1. Loosen :• Valve Adjuster Locknuts ¿• Valve Adjusters À2. Remove :• Stopper Plate Á b

ENGENGINE DISASSEMBLY4-147. AttachValve Spring compression Tool ¿8. Remove :• Valve Cotters ÀNOTE : Valve Spring compressor tool is to be attachedbet

ENGINSPECTION AND REPAIRINSPECTION AND REPAIR:CYLINDER HEAD4-15CYLINDER HEAD1. Remove :• Carbon deposits from combustionchambers using a rounded scrap

GENINFOPREPARATION FOR DISASSEMBLY1. Remove all dirt, mud, dust and foreign ma-terial before disassembly.2. Use proper Tools and Cleaning Equipment.Re

ENGINSPECTION AND REPAIR:VALVE SEATS4-164. Lap :• Valve face• Valve seatNOTE : After refacing the Valve Seat or replacing theValve, the Valve Seat and

ENGINSPECTION AND REPAIRS4-17ææææææææææææææææææææææææææææææææææLapping steps :• Apply coarse lapping compound ç to the ValveFace• Apply molybdenum di

ENGINSPECTION AND REPAIR :VALVE SPRINGS AND VALVES4-182. Measure :• Spring tilt çOut of specification Ÿ ReplaceVALVE SPRINGS AND VALVES1. Measure :•

ENGENGINE INSPECTION AND REPAIR4-19Stem-to-guide clearance limit :Intake :0.010 ~ 0.00370 mm<limit : 0.08 mm>Exhaust :0.025 ~ 0.052 mm<limit

ENGENGINE INSPECTION AND REPAIR4-20ROCKER ARMS AND ROCKER ARMSHAFTS INSPECTION1. Inspect :• Cam lobe contact surface ¿• Adjuster surface ÀWear/pitting

ENGENGINE INSPECTION AND REPAIR4-21TIMING CHAIN, SPROCKETS ANDCHAIN GUIDES1. Inspect :• Timing ChainWear out/Stiffness/damage Ÿ Replace theChain and t

ENGENGINE INSPECTION AND REPAIR4-22CYLINDER AND PISTONS1. Inspect :• Cylinder and Piston wallsVertical scratches Ÿ Rebore or replacethe Cylinder and

ENG15mmENGINE INSPECTION AND REPAIR4-23PISTON RING INSPECTION1. Measure :• Side clearanceOut of specification Ÿ Replace the Pistonand the Piston Rin

ENGPISTON PIN INSPECTION1. Inspect :• Piston PinBlue discoloration/grooves Ÿ Replace andinspect the lubrication system2. Measure :• Piston Pin-to-Pist

ENGENGINE INSPECTION AND REPAIR4-255. Inspect :• Crankshaft journal oil passageClogged Ÿ Blow the oil passage withcompressed air4. Inspect :• Cranksha